Air barrier material application systems and methods

ABSTRACT

A post-cure inflation machine for processing a tire may include a tire holder shaft. The tire holder shaft may include a chuck to secure the tire to the tire holder shaft. A hollow passage may be defined in the tire holder shaft. A spray nozzle may be connected to a spray shaft that is telescopically disposed in the hollow passage of the tire holder shaft. The spray nozzle may extend to spray an air barrier material onto the tire.

BACKGROUND

The present disclosure relates generally to methods and apparatuses forbuilding a tire. More particularly, the present disclosure pertains tobuilding a tire without a typical inner liner and instead spraying on anair barrier material on the inner surface of the tire.

Typical pneumatic tires having inner liners are known in the art. Aninner liner is used because the rubber used for the other portions ofthe tire is too permeable and allows air inside the tire to escape overtime. The inner liner is made from a different and more expensive rubberthat allows much less air to escape the tire over time. Halogenatedrubbers, which are used in inner liners, are, on a pound per poundbasis, the most expensive rubber in a tire. One to two pounds of innerliner rubber is used in a typical passenger tire. Concerns over expense,ease of manufacture, and ultimate finished tire weight make the typicalinner liner undesirable.

What is needed, therefore, is one or more methods and apparatuses thatallow for an inner liner to be sprayed onto the inner surface of thetire.

BRIEF SUMMARY

Briefly, the present disclosure relates, in one embodiment, to a methodof applying an air barrier material to an inner surface of a tire. Themethod may include curing the tire; securing the tire onto a chuck of apost-cure inflation machine; performing a first post-cure inflationcycle; spraying the air barrier material onto the inner surface of thetire while the tire is in a spray position within 25 degrees ofvertical; and axially rotating the tire while the tire is secured on thechuck in the spray position.

The present disclosure also relates, in one embodiment, to a method ofapplying an air barrier material to an inner surface of a tire. Themethod may include performing a post-cure inflation of the tire; placingthe tire onto a dump gate platform after finishing the post-cureinflation of the tire; and spraying the air barrier material onto theinner surface of the tire while the tire is on the dump gate platform.

The present disclosure further relates, in an embodiment, to a method ofapplying an air barrier material to an inner surface of a tire. Themethod may include conveying the tire to a spray area section of aconveyor system; stopping the tire on the spray area section; sprayingthe air barrier material onto the inner surface of the tire while thetire is stopped on the spray area section; and conveying the tire awayfrom the spray area section after spraying the air barrier material ontothe inner surface of the tire.

The present disclosure further still relates, in one embodiment, to amethod of applying an air barrier material to an inner surface of atire. The method may include placing the tire in a tire trimmingmachine; rotating the tire in the tire trimming machine as part of atire trimming operation; and spraying the air barrier material onto theinner surface of the tire while performing the tire trimming operation.

The present disclosure even further relates, in one embodiment, to asprayer apparatus for spraying an air barrier material onto an innersurface of a tire. The sprayer apparatus may include a nozzle. Thenozzle may include at least one material opening defined in the nozzle.The at least one material opening may be configured to project the airbarrier material in a general material direction. At least one first airprojection opening may be defined in the nozzle on a first side of theat least one material opening. At least one second air projectionopening may be defined in the nozzle on a second side of the at leastone material opening. The second side may be opposite the first side.The at least one first air projection opening and the at least onesecond air projection opening may each be configured to project arespective one of two air blades to contain the material between the airblades.

The present disclosure also relates, in one embodiment, to a post-cureinflation machine for processing a tire. The post-cure inflation machinemay include a tire holder shaft. The tire holder shaft may include achuck configured to secure the tire to the tire holder shaft. A hollowpassage may be defined in the tire holder shaft. A spray nozzle may beconnected to a spray shaft. The spray shaft may be telescopicallydisposed in the hollow passage of the tire holder shaft so that thespray nozzle may extend to spray an air barrier material onto the tire.

The present disclosure further still relates, in one embodiment, to aspray area section of a conveyor system for processing a tire. The sprayarea section may include a spray area platform. A sprayer passage may bedefined in the spray area platform. A spray nozzle may be configured topass through the sprayer passage so that the spray nozzle may extend tospray an air barrier material onto the tire.

The present disclosure yet further relates, in one embodiment, to a tiretrimming machine for processing a tire. The tire trimming machine mayinclude at least one centering roller configured to bias the tire into acentered position. At least one blade may be configured to trim thetire. A spray nozzle may be configured to extend to spray an air barriermaterial onto the tire.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a typical pneumatic passenger tire.

FIG. 2 is a flow chart showing the typical steps of creating a pneumatictire.

FIG. 3 is a front elevation view of an embodiment of a post-cureinflation machine for processing pneumatic tires.

FIG. 4 is a side elevation view of the post-cure inflation machine ofFIG. 3 with a first tire undergoing a first post-cure inflation cycleand a second tire not yet mounted to the post-cure inflation machine.

FIG. 5 is a side elevation view of the post-cure inflation machine ofFIG. 3. This figure could show the first tire undergoing a secondpost-cure inflation cycle and the second tire undergoing a firstpost-cure inflation cycle. Alternatively, this figure could show thefirst tire undergoing a first post-cure inflation cycle and the secondtire having been just recently mounted to the post-cure inflationmachine.

FIG. 6 is a side elevation view of the post-cure inflation machine ofFIG. 3. This figure shows the post-cure inflation machine at a sprayingstep wherein the tire being sprayed is in the spray position.

FIG. 7 is a front elevation view of an embodiment of a spray areasection of a conveyor system, the spray area section including a dumpgate.

FIG. 8 is a side elevation view of the spray area section of FIG. 7 withthe sprayer in the retracted position.

FIG. 9 is a side elevation view of the spray area section of FIG. 7 withthe sprayer in the extended position.

FIG. 10 is a side elevation view of an embodiment of a spray areasection of a conveyor system showing a receiving conveyor and ahorizontally mounted sprayer, the spray area section including a dumpgate.

FIG. 11 is a side elevation view of the spray area section of FIG. 10with the dump gate holding the tire in a vertical position while thesprayer applies the air barrier material.

FIG. 12 is a side elevation view of the spray area section of FIG. 10with the dump gate in a dump position to transfer the tire to thereceiving conveyor after the tire has been sprayed with the air barriermaterial.

FIG. 13 is a side elevation view of the spray area section of FIG. 10with the dump gate in the start position to receive a new tire after theprevious tire has been transferred to the receiving conveyor.

FIG. 14 is a front elevation view of an embodiment of a spray areasection of a conveyor system showing a delivery conveyor and a receivingconveyor. The spray area section being similar to that shown in FIGS.7-9, but with no dump gate.

FIG. 15 is a front elevation view of an embodiment of a spray areasection of a conveyor system showing a delivery conveyor and a receivingconveyor.

FIG. 16 is a side elevation view of the spray area section of FIG. 15.The spray area section being similar to that shown in FIGS. 10 and 11,but with no dump gate and with a differently located receiving conveyor.

FIG. 17 is a perspective view of an embodiment of a tire trimmingmachine.

FIG. 18 is a cross-sectional view of the tire trimming machine of FIG.17 including a sprayer in a retracted position.

FIG. 19 is a cross-sectional view of the tire trimming machine of FIG.17 with the sprayer in an extended position and spraying an air barriermaterial onto a tire.

FIG. 20 is a perspective view of a spray booth for spraying an airbarrier material onto a tire.

FIG. 21 is a front elevation view of a spray apparatus for spraying anair barrier material onto an inner surface of a tire.

FIG. 22 is a top plan view of the spray apparatus of FIG. 21 whilespraying the air barrier material.

FIG. 23 is a top plan view of another configuration of the sprayapparatus of FIG. 21 while spraying the air barrier material.

FIG. 24 is a perspective view of a conveyor oven.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the presentdisclosure, one or more drawings of which are set forth herein. Eachdrawing is provided by way of explanation of the present disclosure andis not a limitation. In fact, it will be apparent to those skilled inthe art that various modifications and variations can be made to theteachings of the present disclosure without departing from the scope ofthe disclosure. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment.

Thus, it is intended that the present disclosure covers suchmodifications and variations as come within the scope of the appendedclaims and their equivalents. Other objects, features, and aspects ofthe present disclosure are disclosed in, or are obvious from, thefollowing detailed description. It is to be understood by one ofordinary skill in the art that the present discussion is a descriptionof exemplary embodiments only and is not intended as limiting thebroader aspects of the present disclosure.

The words “connected”, “attached”, “joined”, “mounted”, “fastened”, andthe like should be interpreted to mean any manner of joining two objectsincluding, but not limited to, the use of any fasteners such as screws,nuts and bolts, bolts, pin and clevis, and the like allowing for astationary, translatable, or pivotable relationship; welding of any kindsuch as traditional MIG welding, TIG welding, friction welding, brazing,soldering, ultrasonic welding, torch welding, inductive welding, and thelike; using any resin, glue, epoxy, and the like; being integrallyformed as a single part together; any mechanical fit such as a frictionfit, interference fit, slidable fit, rotatable fit, pivotable fit, andthe like; any combination thereof; and the like.

The words “vertical” and “horizontal” are used for clarity of languageto aid in understanding the disclosure. These words are in reference toorientations of the components when being viewed in an upright positionand do not limit any of the claims to only the upright position.Vertical may, in some embodiments, be associated with an axis along thedirection of gravity. Horizontal, then, may be associated with an axisthat is perpendicular thereto. The terms substantially vertical andsubstantially horizontal may refer to a range that is about truevertical and true horizontal. Substantially vertical should beunderstood to be any orientation with an absolute angle up to 25degrees, and more preferably up to 15 degrees, from an axis along thedirection of gravity. Substantially horizontal should be understood tobe any orientation with an absolute angle of up to 25 degrees, and morepreferably up to 15 degrees, from an axis perpendicular to the directionof gravity.

Unless specifically stated otherwise, any part of the apparatus of thepresent disclosure may be made of any appropriate or suitable materialincluding, but not limited to, metal, alloy, polymer, polymer mixture,wood, composite, or any combination thereof.

Referring to FIG. 1, a typical pneumatic passenger tire 11 is shown. Thetire 11 may be multi-layered and may include tire beads 13, body plies15, at least one cushion 17, steel belts 19, at least one belt wedge 21,gum strips 23, nylon overlays 25, undertread 27, sidewalls 29, and atread portion 31. The typical pneumatic passenger tire 11 also includesan inner liner 33, often a halobutyl, chlorobutyl, or bromobutyl liner.This inner liner 33 is used because the rubber used for the otherportions of the tire 11 is too permeable and allows air inside the tireto escape over time. The inner liner 33 is made from a different andmore expensive rubber that allows much less air to escape the tire overtime. Halogenated rubbers, which are used in inner liners 33, are, on apound per pound basis, the most expensive rubber in a tire 11. One totwo pounds of inner liner rubber is used in a typical passenger tire 11.

As shown in FIG. 2, a typical pneumatic passenger tire 11 is createdaccording to the schematic tire build process. At steps 1 and 2, the rawmaterials are prepared for the building process. At step 3, the fabriccord is calendered and cut into plies, and the steel belt is calenderedand cut. At step 4, the bead is assembled. At step 5, the tread andsidewall is extruded, and the inner liner is calendered. At step 6, thetire is built. At step 7, the tire is cured. At step 8, the tire isinspected in multiple fashions. Finally, the tire is finished and readyfor use or sale.

Post-Cure Inflation Machine and Method Relating Thereto

Turning now to FIGS. 3-6, a post-cure inflation machine 100 is shown.The post-cure inflation machine 100 may receive a tire 35 (with no innerliner) that has recently been cured in a curing press (not shown).

At least one tire holder shaft 102 of the post-cure inflation machine100 may include a chuck 104. The chuck 104 may be configured to securethe tire 35 to the tire holder shaft 102. At least one of the tireholder shaft 102 and the chuck 104 may be configured to rotate about anaxis A1 of the tire holder shaft in some embodiments.

A hollow passage 106 may be defined in the tire holder shaft 102. Aspray nozzle 108 may be connected to a spray shaft 110. The spray shaft110 may be telescopically disposed in the hollow passage 106 of the tireholder shaft 102. This configuration may allow the spray nozzle toextend to spray an air barrier material 112 onto the tire 35.

In some embodiments, the spray nozzle 108 and spray shaft 110 may berigidly connected to a portion of the tire holder shaft 102. The tireholder shaft 102 may be telescopic itself in many embodiments. The sprayshaft 110 may also be configured to extend telescopically along the axisA1 of the tire holder shaft 102. Additionally or alternatively, thespray shaft 110 may be configured to extend telescopically in adirection perpendicular to the axis A1 of the tire holder shaft 102.

A method of applying the air barrier material 112 to an inner surface 37of the tire 35 may be performed with the above described post-cureinflation machine 100. The method may include curing the tire 35, oftenwith a curing press.

After the tire 35 has been cured, the tire may be secured onto the chuck104 of the post-cure inflation machine 100. The tire 35 may be placed onthe tire holder shaft 102 by a robotic arm or a person. The tire 35 maybe placed on the tire holder shaft 102 at the middle-right of FIG. 3,for instance. Once the tire 35 has been received on the tire holdershaft 102, the chuck 104 may be actuated to secure the tire.

Once the tire 35 is secured by the chuck 104, the tire holder shaft 102may rotate around an extender arm axis A2 to position the tire holdershaft to receive another tire on the other end of the tire holder shaft.Additionally or alternatively, the tire holder shaft 102 may rotatearound a base axis A3. The ends of the tire holder shaft 102 may rotateabout the extender arm axis A2 along a path 114 as shown in FIGS. 4-6.

Once the tire holder shaft 102 has rotated once to place the tire 35 ina first position that is substantially horizontal, the tire begins itsfirst post-cure inflation cycle. The bottom tire 35 on FIG. 4 is in thefirst position, for instance. While the bottom tire 35 is undergoing itsfirst post-cure inflation cycle, another tire may be placed on the toppart of the tire holder shaft 102 as shown in FIG. 5.

Between some or all rotations, the tire holder shaft 102 may stop at aspray position that is substantially horizontal as shown in FIG. 6. Thetire 35, then, is substantially vertical. The bottom tire 35 of FIG. 5,having completed its first post-cure inflation cycle, may rotate to thisspray position on the left of FIG. 6. At this position, the tire 35 mayreceive a coating of air barrier material 112 sprayed from the spraynozzle 108. In many embodiments, the tire 35 may be rotated about theaxis A1 of the tire holder shaft during and/or after the sprayingprocess.

In some embodiments, the spray nozzle 108 may extend from inside thetire holder shaft 102 such that the spray nozzle is directed at theinner surface 37 of the tire 35. In these embodiments, the spray nozzle108 may retract back inside the tire holder shaft 102 after completingthe spraying task.

After the spraying step is finished, the tire 35 may then move to asecond position, the top position of the two tires shown in FIG. 5, toundergo a second post-cure inflation cycle.

Additionally or alternatively, the tires 35 may receive a coating of airbarrier material 112 sprayed from the spray nozzle 108 after the secondpost-cure inflation cycle. In some embodiments, the tire 35 may receivea coating of air barrier material 112 sprayed from the spray nozzle 108during the second post-cure inflation cycle.

Dump Gate Assembly and Method Relating Thereto

In FIGS. 7-9, an embodiment of a spray area section 200 of a conveyorsystem is shown. With regard to FIGS. 7-9, the spray area section 200 isa dump gate assembly.

The dump gate assembly 200 may include a dump gate platform 202 forsupporting the tire 35. In many embodiments, the dump gate platform 202may include a plurality of rollers 204. The rollers 204 may be of anyappropriate construction and may include bar rollers, ball bearing typerollers, conveyor belts, wheels, actuated sections of the spray areaplatform 202, and the like.

A spray passage 206 may be defined in the dump gate platform 202. Thisspray passage 206 may, in some embodiments, include a missing roller 204or a gap between rollers, conveyor belts, and the like. A spray nozzle208 may be configured to pass through the spray passage 206. The spraynozzle 208 may extend from below the dump gate platform 202 to above thedump gate platform by a telescopic spray shaft 210 in some embodiments.The spray nozzle 208 may extend to a position to spray an air barriermaterial 212 onto the tire 35.

A dump gate wall 214 may be positioned substantially orthogonally to thedump gate platform 202. The dump gate wall 214 may also include rollers204 of any appropriate construction. At least one drive roller 216 maybe disposed on the dump gate wall 214 to rotate the tire 35 about thetire axis A4 on the dump gate platform 202. The rest of the rollers 204disposed on the dump gate wall 214 and the dump gate platform 202 may beconfigured to allow this rotation of the tire 35. Additionally oralternatively, the spray nozzle 208 may be configured to rotate on thespray shaft 210 during the spray operation.

A method of applying the air barrier material 212 to an inner surface 37of the tire 35 may be performed with the above described spray areasection 200. The method may include performing a post-cure inflation ofthe tire 35.

After the post-cure inflation process has been completed, the tire 35may be placed on the dump gate platform 202. The tire 35 may be placedon the dump gate platform 202 by a robotic arm or a person.

While the tire 35 is on the dump gate platform 202, the air barriermaterial 212 is sprayed onto the inner surface 37 of the tire. This stepmay be accomplished by first extending the spray nozzle 208 from belowthe dump gate platform 202. In some embodiments, the spray shaft 210 istelescopically elongated to extend the spray nozzle 208. The spraynozzle 208 may then be directed at the inner surface 37 of the tire 35.After the spraying step is completed, the spray nozzle 208 may beretracted back to a position below the dump gate platform 202. In someembodiments, the spray shaft 210 telescopically retracts to retract thespray nozzle 208.

The tire 35 may then be removed from the dump gate assembly 200 by arobotic arm, a person, or (as discussed below) may be released from thedump gate assembly by rotating the dump gate wall 214 away from the dumpgate platform 202 to allow the tire to fall and come to rest on aconveyor belt.

Another embodiment of a spray area section, or dump gate assembly, 300of a conveyor system is shown in FIGS. 10-13.

Like components to those shown in FIGS. 7-9 with respect to the dumpgate assembly 200 are repeated in FIGS. 10-13 with a reference numeralthat begins with a three instead of a two. As such, some of thereference numerals shown in FIGS. 10-13 may not otherwise be mentionedherein.

The dump gate assembly 300 may not include an opening or passage in thedump gate platform 302. Instead, the dump gate assembly 300 may beconfigured to move from a first position (shown in FIGS. 10 and 13) withthe dump gate platform 302 substantially horizontal to a second position(shown in FIG. 11) with the dump gate platform substantially vertical.With the dump gate platform 302 in the second position, the tire 35 isalso positioned substantially vertically and rests on the dump gate wall314.

The spray shaft 310 may be mounted to a sprayer tower 318 such that thespray nozzle 308 may extend substantially parallel with the groundtoward the tire 35.

As discussed briefly above, the dump gate wall 314 may be configured torotate in a direction D1 (up and into the page of FIG. 12) away from thedump gate platform 302 to allow the tire 35 to fall and come to rest ona conveyor belt 320. The conveyor belt 320 may be positioned to receivethe tire 35 and to carry the tire away from the dump gate assembly 300and toward another component of the tire manufacturing process.

A method of applying the air barrier material 312 to an inner surface 37of the tire 35 may be performed with the above described spray areasection 300. The method may include performing a post-cure inflation ofthe tire 35.

After the post-cure inflation process has been completed, the tire 35may be placed on the dump gate platform 302. The tire 35 may be placedon the dump gate platform 302 by a robotic arm or a person.

The tire may come to rest on the dump gate platform 302 in a firstposition that is substantially horizontal, as shown in FIG. 10. Next, asshown in FIG. 11, the tire may be moved into a spray position that issubstantially vertical. This step may be accomplished by rotating thedump gate assembly 300 about a pivot point 322. This rotation may beaccomplished by a motor connected to a portion of the dump gate assembly300, a human actuating the rotation, and the like. Once the tire is inthe substantially vertical position, the spray nozzle 308 extends towardthe tire 35 such that the spray nozzle may spray air barrier material312 onto the inner surface 37 of the tire. A spraying step is performedwhile the tire 35 is rotated about its axis A4 by the at least one driveroller 316 on the dump gate wall 314. After the spraying step iscompleted, the spray nozzle 308 retracts toward the spray tower 318, andthe dump gate assembly 300 is rotated back to the first position, asshown in FIG. 10. Additionally or alternatively, the dump gate assembly300 may be rotated to the release position, as shown in FIG. 12. In therelease position, the dump gate wall 314 may be rotated in a directionD1 (represented by an arrow indicating up and into the page of FIG. 12)such that it no longer obstructs the tire 35 in its path to the conveyorbelt 320. After the tire has passed to the conveyor belt 320, the dumpgate assembly 300 moves back to the first position to receive the nexttire, as shown in FIG. 13.

Conveyor System Assembly and Method Relating Thereto

Another embodiment of a spray area section 400 of a conveyor system 424is shown in FIG. 14.

Like components to those shown in FIGS. 7-9 with respect to the dumpgate assembly 200 are repeated in FIG. 14 with a reference numeral thatbegins with a four instead of a two with regard to the spray areasection 400. As such, some of the reference numerals shown in FIG. 14may not otherwise be mentioned herein.

The spray area section 400 may function largely in the same way as thedump gate assembly 200, except the spray area section may not includethe release function as discussed above with regard to the dump gateassemblies 200, 300. Instead, the spray area section 400 may beconfigured to receive the tire 35 from an upstream portion of theconveyor system 424. They spray area section 400 may also be configuredto deliver the tire 35 to a downstream portion of the conveyor system424. The portions of the conveyor system 424 other than the spray areasection 400 may include a conveyor belt 420, rollers 404, wheels,actuated portions of a platform, a shaker table, and the like.

A method of applying the air barrier material 412 to an inner surface 37of the tire 35 may be performed with the spray area section 400. Thismethod may include conveying the tire to the spray area section 400 of aconveyor system 424. After the tire 35 has reached the spray areasection 400, the tire is stopped. This stopping function may beperformed by an unactuated drive roller 416 in the spray area platform402 or by a drive roller briefly rolling in a direction opposite thedirection of the tire's momentum. While the tire 35 is stopped on thespray area section 400, the spray nozzle 408 extends from below thespray area platform 402 to above the spray area platform. The spraynozzle 408 sprays air barrier material (not shown) onto the innersurface 37 of the tire. After the spraying step is completed, the spraynozzle 408 retracts back to below the spray area platform 402. The tireis then conveyed away from the spray area section 400. This conveyancemay be initiated by a drive roller 416 in the spray area platform 402,and the tire 35 may be further carried away by downstream rollers 404(or a conveyor belt, wheels, actuated portions of a platform, shakertables, and the like).

In some embodiments, one or more drive rollers 416 in the spray areawall 414 may rotate the tire about its axis A4 during the sprayoperation. Additionally or alternatively, the spray nozzle 408 mayrotate about the spray shaft 410 during the spray operation.

Another embodiment of a spray area section 500 of a conveyor system 524is shown in FIGS. 15 and 16.

Like components to those shown in FIGS. 10-13 with respect to the dumpgate assembly 300 are repeated in FIGS. 15 and 16 with a referencenumeral that begins with a five instead of a three. As such, some of thereference numerals shown in FIGS. 15 and 16 may not otherwise bementioned herein.

The spray area section 500 may function largely in the same way as thedump gate assembly 300, except the spray area section may not includethe release function as discussed above with regard to the dump gateassemblies 200, 300. Instead, the spray area section 500 may beconfigured to receive the tire 35 from an upstream portion of theconveyor system 524 and to deliver the tire to a downstream portion ofthe conveyor system (like conveyor system 424 of FIG. 14 discussedabove).

A method of applying the air barrier material 512 to an inner surface 37of the tire 35 may be performed with the spray area section 500. Thismethod may include conveying the tire to the spray area section 500 of aconveyor system 524. After the tire 35 has reached the spray areasection 500, the tire is stopped in a manner similar to the spray areasection 400. The tire is stopped on the spray area platform 502 in asubstantially horizontal position (shown in FIGS. 15 and 16). While thetire is stopped on the spray area platform 502, the tire is moved to aspray position that is substantially vertical (similar to the dump gateassembly 300 shown in FIG. 11) by rotating the spray area section 500about the pivot point 522. In the spray position, the tire 35 may besupported by the rollers 504 including at least one drive roller 516 ofthe spray area wall 514. Also similar to the discussion above withregard to the dump gate assembly 300, the tire 35 may be rotated aboutits axis A4 by actuating the at least one drive roller 516. While thetire 35 is rotating, the air barrier material is sprayed from the spraynozzle 508 to coat the inner surface 37 of the tire. When the sprayingstep is completed, the tire 35 returns to the substantially horizontalposition by rotating the spray area section 500 about the pivot point522 once more. Once the tire 35 has returned to the substantiallyhorizontal position, as shown in FIGS. 15 and 16, the tire is thenconveyed away from the spray area section 500. As with the spray areasection 400 discussed above, a drive roller 516 in the spray areaplatform 502 may move the tire 35 to downstream rollers 504 and thelike.

Tire Trimming Machine and Method Relating Thereto

In FIGS. 17-19, an embodiment of a tire trimming machine 600 is shown.The tire trimming machine 600 may include at least one tire receivingplatform 602. The tire support platform may include rollers 604 in theform of conveyor belts, wheels, bearings, and the like. The rollers 604may also be driven rollers 616 to move the tire 35 into the correctposition. The tire receiving platform 602 may include a sprayer passage606 to allow a spray nozzle 608 to extend from below the tire supportplatform to above the tire support platform. The spray nozzle 608 may beextended by a telescoping spray shaft 610 such that the spray nozzle maydirect air barrier material 612 at the inner surface 37 of the tire 35.

The tire trimming machine 600 may further include at least one centeringroller 626. The centering roller 626 may be configured to bias the tire35 into a centered position (as shown in FIGS. 18 and 19). In someembodiments, the centering roller 626 may include one or more conicalrollers. The centering rollers may also include drive rollers 616 suchthat the tire is rotated about its axis A4.

At least one blade 628 may be configured to trim the tire 35 as it spinsabout its axis A4.

Although the tire trimming machine 600 is shown configured to maintainthe tire 35 in a substantially horizontal position, it is contemplatedthat another embodiment of a tire trimming machine may maintain the tirein a substantially vertical position. It is even contemplated that anembodiment of a tire trimming machine may receive the tire 35 in asubstantially horizontal position, move the tire to a substantiallyvertical position for the spraying operation, and return the tire to thesubstantially horizontal position before conveying the tire away fromthe tire trimming machine. In such embodiments, the at least onecentering roller 626 may be further configured to hold the tire 35 in afirst position that is substantially vertical.

A method of applying the air barrier material 612 to an inner surface 37of the tire 35 may be performed with the tire trimming machine 600. Thismethod may include placing the tire 35 in the tire trimming machine 600.Once the tire 35 is in place, centering the tire in the tire trimmingmachine 600 with at least one centering roller 626. After the tire 35has been centered, rotating the tire in the tire trimming machine withat least one drive roller 616 as part of a tire trimming operation.Either prior to starting to rotate the tire 35 about its axis A4 orwhile the tire is rotating, extending the spray nozzle 608 from belowthe tire receiving platform 602 to above the tire receiving platformsuch that the spray nozzle is directed at the inner surface 37 of thetire. While trimming the tire 35 with the at least one blade 628,spraying the air barrier material 612 onto the inner surface 37 of thetire. After the spraying operation is completed, retracting the spraynozzle 608 back to below the tire receiving platform 602.

Spray Booth and Method Relating Thereto

In FIG. 20, an embodiment of a spray booth 700 is shown. The spray booth700 may be a designated location for spraying the air barrier material712 onto the tire 35 to prevent overspray. The spray nozzle 708 may bemounted to a portion of the spray booth 700 by the spray shaft 710. Insome embodiments, the spray shaft 710 may be telescopic such that thespray shaft may extend and retract to position the spray nozzle 708correctly depending on the size of the tire 35 placed in the spraybooth. The spray booth 700 may be a part of the assembly line of thetire 35, or it may be separate from such an assembly line. A robotic armor a human may place the tire 35 in the spray booth and may similarlyremove the tire from the spray booth after the spraying operation hascompleted. The spray booth 700 may be a partial or complete enclosure,depending on the embodiment. The tire 35 may rotate about its axis A4,or the spray nozzle 708 may rotate about the spray shaft 710, or bothduring the spraying operation.

Although the spray booth 700 is shown configured to maintain the tire 35in a substantially horizontal position, it is contemplated that anotherembodiment of a spray booth may maintain the tire in a substantiallyvertical position. It is even contemplated that an embodiment of a spraybooth may receive the tire 35 in a substantially horizontal position,move the tire to a substantially vertical position for the sprayingoperation, and return the tire to the substantially horizontal positionbefore conveying the tire away from the spray booth.

Sprayer Apparatus and Method Related Thereto

As shown in FIGS. 21-23, any of the spray nozzles 108, 208, 308, 408,508, 608, and 708 and spray shafts 110, 210, 310, 410, 510, 610, and 710discussed herein may be of a particular construction in someembodiments.

A sprayer apparatus 800 for spraying an air barrier material 812 mayinclude a spray nozzle 808 and a spray shaft 810. The spray nozzle 808may be part of a spray head 830.

The spray nozzle 808 may include at least one material opening 832defined in the nozzle. The at least one material opening 832 may beconfigured to project the air barrier material 812 in a general materialdirection D2.

At least one first air projection opening 834 may be defined in thespray nozzle 808 on a first side of the at least one material opening832. At least one second air projection opening 836 may be defined inthe spray nozzle 808 on a second side of the at least one materialopening 832. The second side may be opposite the first side. The atleast one first air projection opening 834 may be configured to projecta first air blade 838. The at least one second air projection opening836 may be configured to project a second air blade 840. The at leasttwo air blades 838, 840 may be configured to contain the air barriermaterial 812 therebetween.

As shown in FIG. 22, the air blades 838, 840 may be directedsubstantially parallel to the general material direction D2 such thatthe air barrier material 812 projects substantially completely parallelto the general material direction. As shown in FIG. 23, however, thespray nozzle 808 may alternatively be configured such that the airblades 838, 840 form angles with respect to the general materialdirection D2. In this configuration, the air barrier material 812 mayproject in a more fanned out pattern along the general materialdirection D2. In further still configurations, the spray nozzle 808 mayinclude air blades 838, 840 (and perhaps additional air blades)positioned and aimed such that FIG. 22 represents a side view of thespray pattern and FIG. 23 represents a top view of the spray pattern.

More than two air blades 838, 840 are contemplated herein. Less than twoair blades 838, 840 is also contemplated. In some embodiments, the airblades may be of a proper number to form any polygonal shape about theat least one material opening 832. In one embodiment, the air blade maybe formed by a single opening forming a circle about the at least onematerial opening 832. No matter the number of air blades, the airprojection opening(s) are configured to form a virtual spray enclosurefor the air barrier material 812.

Air Barrier Material Curing Oven

The current disclosure contemplates a need for baking the tire 35 havingthe inner surface 37 coated with an air barrier material in order tocure the air barrier material. As such, a conveyor type curing oven 900is shown in FIG. 23. This conveyor type curing oven 900 would allow thetires 35 to continue moving along an assembly line. It is alsocontemplated, however, that the tires 35 could be removed from theassembly line, placed in a large oven (for instance, a walk-in, heatedroom), cured for a period of time, removed, and returned to the assemblyline.

It is also contemplated that embodiments of the air barrier materialcurrently developed or hereinafter developed may not require curing withan oven of any sort. In embodiments with self-curing air barriermaterial, no oven would be required.

This written description uses examples to disclose the invention andalso to enable any person skilled in the art to practice the invention,including making and using any devices or systems. The patentable scopeof the invention is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal language of the claims.

Although embodiments of the disclosure have been described usingspecific terms, such description is for illustrative purposes only. Thewords used are words of description rather than limitation. It is to beunderstood that changes and variations may be made by those of ordinaryskill in the art without departing from the spirit or the scope of thepresent disclosure, which is set forth in the following claims. Inaddition, it should be understood that aspects of the variousembodiments may be interchanged in whole or in part. While specific usesfor the subject matter of the disclosure have been exemplified, otheruses are contemplated. Therefore, the spirit and scope of the appendedclaims should not be limited to the description of the versionscontained herein.

What is claimed is:
 1. A method of applying an air barrier material toan inner surface of a tire, the method comprising: (a) curing the tire;(b) after curing the tire, securing the tire onto a chuck of a post-cureinflation machine; (c) performing a first post-cure inflation cycle; (d)spraying the air barrier material onto the inner surface of the tirewhile the tire is in a spray position within 25 degrees of vertical; and(e) axially rotating the tire while the tire is secured on the chuck inthe spray position.
 2. The method of claim 1, wherein the firstpost-cure inflation cycle is performed with the tire in a first positionwithin 25 degrees of horizontal.
 3. The method of claim 2, wherein step(d) includes extending a spray nozzle from inside a shaft connected tothe chuck of the post-cure inflation machine such that the spray nozzleis directed at the inner surface of the tire.
 4. The method of claim 3,further comprising: after completing step (c), moving the tire to thespray position; and after completing step (d), moving the tire to asecond position within 25 degrees of horizontal to commence a secondpost-cure inflation cycle.
 5. The method of claim 3, wherein at least aportion of a second post-cure inflation cycle is performed during step(d).
 6. The method of claim 3, further comprising: after completing step(d), retracting the spray nozzle back inside the shaft of the post-cureinflation machine.
 7. The method of claim 3, further comprising: movingthe tire to a second position within 25 degrees of horizontal aftercompleting step (c); performing a second post-cure inflation cycle withthe tire at the second position; moving the tire to the spray positionafter the second post-cure inflation cycle; and performing steps (d) and(e) after the tire is moved to the spray position from the secondposition.
 8. The method of claim 1, wherein steps (d) and (e) overlaptemporally.